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5

 

 

ELECTRIC

 

SHOCK

 

 

Electric

 

shock

 

can

 

injure

 

or

 

kill!

 

 

Precautionary

 

measures

 

must

 

be

 

taken

 

to

 

provide

 

maximum

 

protection

 

against

 

electri

cal

 

shock.

  

 

♦ 

Do

 

not

 

touch

 

live

 

or

 

energized

 

electrical

 

parts

 

or

 

store

 

metallic

 

objects

 

near

 

power.

 

♦ 

Ground

 

the

 

work

 

or

 

metal

 

to

 

be

 

welded

 

to

 

a

 

good

 

electrical

 

(earth)

 

ground.

 

♦ 

Do

 

not

 

leave

 

an

 

energized

 

machine

 

unattended.

 

♦ 

Never

 

work

 

in

 

wet

 

clothing,

 

gloves

 

or

 

footwear.

 

♦ 

Insulate

 

yourself

 

from

 

work

 

and

 

ground

 

using

 

dry

 

insulation.

 

Make

 

certain

 

the

 

insulation

 

is

 

large

 

enough

 

to

 

cover

 

your

 

full

 

area

 

of

 

physical

 

contact

 

with

 

work

 

and

 

ground.

 

♦ 

Inspect

 

all

 

system

 

components,

 

protective

 

equipment,

 

cables,

 

connectors

 

and

 

gas

 

lines

 

prior

 

to

 

operating

 

equipment.

 

Never

 

use

 

cables

 

that

 

are

 

longer

 

than

 

necessary.

 

♦ 

When

 

testing

 

a

 

live

 

unit,

 

use

 

the

 

one

hand

 

method.

 

Do

 

not

 

put

 

both

 

hands

 

inside

 

of

 

the

 

unit.

 

Keep

 

one

 

hand

 

free.

 

♦ 

Disconnect

 

input

 

power

 

conductors

 

from

 

de

energized

 

supply

 

line

 

before

 

moving

 

a

 

welding

 

power

 

source.

 

♦ 

Always

 

be

 

sure

 

the

 

work

 

cable

 

makes

 

a

 

good

 

electrical

 

connection

 

with

 

the

 

metal

 

being

 

welded.

 

The

 

connection

 

should

 

be

 

as

 

close

 

as

 

possible

 

to

 

the

 

area

 

being

 

welded.

 

♦ 

Turn

 

OFF

 

welding

 

power

 

source

 

before

 

servicing

 

unless

 

the

 

procedure

 

specifically

 

requires

 

an

 

energized

 

unit.

 

♦ 

Never

 

touch

 

the

 

energized

 

stud

 

or

 

gun

 

before

 

discharging

 

the

 

stud

 

to

 

ground.

 

♦ 

Never

 

use

 

the

 

power

 

source

 

to

 

provide

 

heat

 

for

 

thawing

 

frozen

 

pipes.

 

 

ARC

 

RAYS

 

and

 

EYE

 

PROTECTION

 

 

Arc

 

rays

 

can

 

injure

 

eyes

 

and

 

burn

 

skin.

  

Arc

 

flashes

 

are

 

painful.

 

 

♦ 

Use

 

a

 

shield

 

with

 

the

 

proper

 

filter

 

and

 

cover

 

plates

 

to

 

protect

 

your

 

eyes

 

from

 

sparks

 

and

 

the

 

rays

 

of

 

the

 

arc

 

when

 

welding

 

or

 

while

 

observing

 

open

 

arc

 

welding.

 

♦ 

Use

 

protective

 

clothing

 

specifically

 

intended

 

for

 

work

 

with

 

welding

 

equipment.

 

It

 

should

 

be

 

made

 

of

 

durable

 

flame

resistant

 

material

 

to

 

provide

 

ample

 

protection

 

from

 

the

 

arc

 

rays.

 

♦ 

Protect

 

other

 

nearby

 

workers

 

with

 

suitable,

 

non

flammable

 

screening.

 

Caution

 

other

 

workers

 

not

 

to

 

watch

 

the

 

arc

 

nor

 

expose

 

themselves

 

to

 

the

 

arc

 

rays

 

or

 

to

 

hot

 

spatter

 

or

 

metal.

 

Stud

 

Welding

 

Safety

 

Precautions

 

Summary of Contents for ARWSC900

Page 1: ...y integrated stud welding system for ferrule shielded and gas shielded drawn arc stud welding The SC900 con tains digital controls for weld time weld current and gas purge time The system was designed...

Page 2: ...which has been modified Equipment which has not been installed properly Equipment which has been used for purposes other than which it had been designed Equipment which has not been properly maintain...

Page 3: ...cess and growth If we can be of any further assistance to you and your company please do not hesitate to contact us Product Information The SC900 is a fully integrated stud welding system for ferrule...

Page 4: ...esigned and built with operator safety in mind but safety begins with you Every effort has been made to protect the trained operator from injury Please become familiar with the information in this man...

Page 5: ...ne before moving a welding power source Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being wel...

Page 6: ...the area being welded Keep welding power source and cables as far away from your body as possible Electromagnetic fields can irrevocable erase magnetic data carriers computer memory credit cards secu...

Page 7: ...welding interlock keeps system from double triggering SC900 Product Specifications Specifications are subject to change without prior notification Weld Range 14ga to 1 2 Consistent welding regardless...

Page 8: ...ng materials that may obstruct airflow through the welder If the equipment is not being installed immediately store it in a clean dry well ventilated area until in stallation Selecting a Location The...

Page 9: ...made are accessi ble with the top cover removed Primary Power Cable Route the Primary Power Cable through the Power Inlet Hole in the center connector on the back side of the welder Connect the power...

Page 10: ...line voltages depending on your requirements Simply plug in the appropriate voltage con nector for either 230VAC red wired connector or 460VAC black wired connector 3 Phase opera tion Ground Cable Co...

Page 11: ...front of the welder Connect stud gun cable assembly directly to the SC900 Plug stud gun control cable plug into the connector on the front of welder Gas line connection When gas shield welding connect...

Page 12: ...stud to be welded After all of the proper accessories have been mounted on the stud gun place the stud in the chuck and begin the alignment of the accessories Make certain that a sufficient amount of...

Page 13: ...nging in diameter through 3 4 this adjustment should be suitable For larger diameter studs and select applications the lift should be adjusted to approximately 1 8 Adjusting the lift Remove the back c...

Page 14: ...an be used to control the force with which the stud is plunged into the molten weld pool by moving the engagement point of when the shaft of the stud gun engages the damp ener Rotating the dampener co...

Page 15: ...complete the circuit and actuate the stud gun Make sure welder is set up properly to begin the welding process Place the selected stud into the chuck and attach the ferrule to the ferrule grip Place s...

Page 16: ...e 3 times indicating that there is a good connection SC900 Diagnostic Lights On the Control Panel located below the digital display is a row of diagnostic lights for the welder OUTPUT When the stud gu...

Page 17: ...chosen during setup When setting time or current depress and hold down appropriate button and turn Adjustment Dial clockwise or counter clockwise to the correct setting on the digital display Use the...

Page 18: ...was drawn or not Job Counter Resettable This is a running total of the number of welds since the counter was last reset To view the job counter set the Fine Coarse Switch to the Fine position Each wel...

Page 19: ...gs from being adjusted The purpose is to allow a meas ure of process control All settings and the counter may be viewed when the lock is activated To activate the lock turn clockwise toward the 3 o cl...

Page 20: ...weld The main spring plunges the weld stud down into the molten pool of metal in the base material The cycle is completed in less than a second and the resulting weld bond develops the full strength o...

Page 21: ...ud pro trudes beyond the ferrule Make sure work surface is relatively clean so impurities do not affect weld Test the welds at the beginning of each shift or change in stud Check burn off 1 8 color si...

Page 22: ...a bumpy or jagged collar around the base of the weld stud This normally occurs when the weld time is set too high Porous Weld Collar This usually occurs from the oxidation of the weld pool resulting...

Page 23: ...o lift from gun coil trigger is good Bad connection or faulty equipment 1 Test control cable by plugging weld tool directly into unit 4 conductor straight through wiring 2 Check 5 amp fuse next to bre...

Page 24: ...and connections in cluding grounds 3 Test the power loop by making welds on a test piece us ing only the starter cable set 4 Test 3 phase power to control contactor 5 Check taps if applicable on main...

Page 25: ...25 TRU WELD Equipment Company 6400 N Honeytown Road Smithville Ohio 44677 330 725 7744 Phone 330 669 2473 Fax TWE tfpcorp com http truweldstudwelding com...

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